Electronic circuit control element with tap element

ABSTRACT

A technique for controlling a power supply with power supply control element with a tap element. In one embodiment, a power supply regulator includes a power transistor having first, second, third and fourth terminals. A control circuit is included, which is coupled to the third and fourth terminals of the power transistor. The power transistor is configured to switch a current between the first and second terminals in response a control signal received from the control circuit at the third terminal. A voltage between the fourth and second terminals of the power transistor is substantially proportional to a current flowing between the first and second terminals when a voltage between the first and second terminals is less than a pinch off voltage. The voltage between the fourth and second terminals of the power transistor is substantially constant and less than the voltage between the first and second terminals when the voltage between the first and second terminals is greater than the pinch off voltage.

This is a Continuation of U.S. application Ser. No. 10/446,312, filedMay 27, 2003 now U.S. Pat. No. 6,865,093, now pending.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to control elements used inelectronic circuits and, more specifically, the present inventionrelates to control elements with integrated power transistors.

2. Background Information

Two of the primary goals in the design of control elements withintegrated power transistors are cost and performance. Cost is generallyreduced when the number of external components required in theelectronic circuit are reduced, and when smaller, more efficient powertransistors are employed. Performance may be improved by adopting a moreefficient power transistor, which increases efficiency, and by loweringthe manufacturing variance, which allows better control of criticalparameters such as the peak current delivered by the power transistor.

FIG. 1 shows a power supply 10, which is provided as an example of anelectronic circuit using a control element with power transistor. Thecontrol element 22 for this known power supply 10 includes a controlcircuit 23 and a separate power transistor 21. In power supply 10, thestart-up function is performed by resistor 32, which provides the highvoltage DC from bridge rectifier 12 to the control circuit 23.Unfortunately, resistor 32 is expensive, requires a large area in thepower supply and lowers supply efficiency by dissipating powercontinuously, even after the start-up function is completed. The currentlimit function of power supply 10 is provided by a sense resistor 33that is in series with the source of power transistor 21. The voltageacross resistor 33, which increases with increasing current throughpower transistor 21, is coupled to the control circuit 23. When thecurrent through power transistor 21 reaches a predetermined level, thecontrol circuit 23 turns of power transistor 21. Drawbacks of thisapproach are the cost, size and power dissipation of resistor 33.

FIG. 2 shows a known power supply 50 similar to power supply 10, exceptthat resistor 32 has been eliminated. A voltage regulator internal topower supply chip 52 now performs the start-up function. The voltageregulator in power supply chip 52 may be turned off after the start-upfunction is completed, thus eliminating the extra power dissipationinherent to power supply 10. However, the voltage regulator in powersupply chip 52 includes a high-voltage offline transistor 54 thatconsumes a significant area on power supply chip 52 and is also prone toelectrical static discharge (ESD) and safe operating area (SOA) damage.

FIG. 3 shows a known power supply 70 that avoids some of the problems ofpower supplies 10 and 50. Power supply 70 does not require a start-upresistor 32 or a high-voltage offline transistor 54. Instead, a tap 90at the junction between junction field effect transistor (JFET) 86 andinsulated gate field effect transistor (IGFET) 88 of metal oxidesemiconductor field effect transistor (MOSFET) 84 is used to perform thestart-up function. Tap 90 may also be used to monitor the voltage forperforming the current limit function, obviating the need for a separatesense resistor. The main limitation of this approach is that the MOSFET84 used in power supply 70 is limited to one that can be monolithicallyintegrated on the chip 82. In some cases, discrete power devices withhigher efficiency may be available, but cannot be employed in themonolithic approach of power supply 70.

SUMMARY OF THE INVENTION

An integrated control element with power transistor and tap element isdisclosed. In one embodiment, a control element according to embodimentsof the present invention includes a power transistor having first,second, third and fourth terminals. A control circuit is included, whichis coupled to the third and fourth terminals of the power transistor.The power transistor adapted to switch a current between the first andsecond terminals in response a control signal to be received from thecontrol circuit at the third terminal. A voltage between the fourth andsecond terminals of the power transistor is substantially proportionalto a current flowing between the first and second terminals when avoltage between the first and second terminals is less than a pinch offvoltage. The voltage between the fourth and terminals of the powertransistor is substantially constant and less than the voltage betweenthe first and second terminals when the voltage between the first andsecond terminals is greater than or equal to the pinch off voltage.

A high voltage transistor according to embodiments of the presentinvention includes a drain region having a first conductivity type. Thetransistor also includes at least one source region having the firstconductivity type. At least one body region having a second conductivitytype opposite to the first conductivity type is included in thetransistor. The at least one body region adjoins the source region. Thetransistor includes at least one drift region having the firstconductivity type and adjoining at a first end the drain region. The atleast one drift region extends from the first end to adjoin at a secondend the at least one body region. The at least one source region isseparated from the second end of the at least one drift region by the atleast one body region. The transistor further includes a tap region of afirst conductivity type and a tap drift region extending from the tapregion to the drain region. The transistor also includes an insulatedgate adjacent to the at least one body region.

Additional features and benefits of the present invention will becomeapparent from the detailed description, figures and claims set forthbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention detailed illustrated by way of example and notlimitation in the accompanying figures.

FIG. 1 is a schematic diagram of a known power supply that includes aseparate control circuit and power transistor. A high voltage resistoris used to perform the start-up function and a sense resistor is used toprovide the current limit function.

FIG. 2 is a schematic diagram of a known power supply that includes anintegrated control circuit and power transistor. A separate offlinetransistor is used to perform the start-up function.

FIG. 3 is a schematic diagram of a known power supply that includes anintegrated control circuit and power transistor. A tap in the integratedpower transistor provides the start-up and current limit functions.

FIG. 4 is a schematic diagram of one embodiment of a power supplycontrol element with a tap element in accordance with the teachings ofthe present invention.

FIG. 5 is a diagram illustrating the relationship between the voltageacross the drain and source terminals and a tap element of oneembodiment of a power transistor in accordance with the teachings of thepresent invention.

FIG. 6 is a diagram illustrating a cross-sectional side view of oneembodiment of a power transistor in accordance with the teachings of thepresent invention.

FIG. 7 is a diagram illustrating a cross-sectional side view of anotherembodiment of a power transistor in accordance with the teachings of thepresent invention.

DETAILED DESCRIPTION

A novel control element including a power transistor with a tap elementis disclosed. In the following description, numerous specific detailsare set forth in order to provide a thorough understanding of thepresent invention. It will be apparent, however, to one having ordinaryskill in the art that the specific detail need not be employed topractice the present invention. In other instances, well-known materialsor methods have not been described in detail in order to avoid obscuringthe present invention.

The following description uses the example of a power supply toillustrate the benefits of the present invention. It will be apparent toone skilled in the art that the techniques are not limited to use inpower supplies but apply to any electronic circuit employing a controlelement with integrated power transistor.

In general, a power supply according to embodiments of the presentinvention includes a power control element that includes a controlcircuit and a power transistor. The control circuit and power transistormay be packaged together in a single package. A power transistoraccording to embodiments of the present invention includes a tap elementthat provides a voltage proportional to the current flowing through thepower transistor when the voltage across the main terminals of the powertransistor is less than a pinch off voltage. In one embodiment, when thevoltage across the main terminals of the power transistor is greaterthan or equal to the pinch off voltage, the voltage provided at the tapelement is substantially fixed at a voltage, which may be substantiallyless than the voltage across the main terminals of the power transistor.

In one embodiment, the tap element may be used for a start-up functionfor the power supply control element. In this embodiment, current isdrawn from a main terminal of the power transistor through the tapelement and into the control circuit.

In another embodiment, the tap element may be used to provide a signalfor a current limit function of the power supply control element. Inthis embodiment, the tap element provides a voltage to the controlcircuit that is proportional to the current flowing through the powertransistor.

In other embodiment, the tap element may be used provide otherfunctions, such as for example sensing the voltage across the mainterminals of the power transistor when the power transistor is in theoff state. In addition, several or all of these functions may berealized in the same power supply control element.

To illustrate, FIG. 4 shows generally a schematic diagram of a powersupply control element 82 in a power supply 70 according to embodimentsof the present invention. In operation, alternating current (AC) voltageis rectified and filtered with rectifier 72 and capacitor 81. Energytransfer element 74 is coupled to receive the rectified voltage fromrectifier 72 with primary winding 76. Energy transfer element alsoincludes output winding 78 and bias winding 80. Energy is transferredacross energy transfer element 74 from primary winding 76 to outputwinding 78 and bias winding 80 in response to power supply controlelement 82.

In one embodiment, power supply control element 82 includes controlcircuit 83 and power transistor 88 having main terminals 89 and 91, atap element 90, a tap terminal 94 and a control terminal 93. In oneembodiment, the main terminals 89 and 91 are the drain and sourceterminals, respectively, and control terminal 93 is the gate terminal ofa power transistor 88 in accordance with the teachings of the presentinvention. In one embodiment, power transistor 88 is a metal oxide fieldeffect transistor (MOSFET).

As shown in the depicted embodiment, main terminal 89 is coupled toprimary winding 76 of energy transfer element 74. In operation, powertransistor 88 is switched on and off to regulate the transfer of powerfrom primary winding 76 to output winding 78 and bias winding 80. Forexample, in one embodiment, a feedback signal is received from the biaswinding 80 through Vbias 112. Pulse width modulator (PWM) 104 is coupledto control terminal 93 to provide a control signal to switch powertransistor 88 on and off in response to Vbias 112. It is appreciated ofcourse that other configurations of switched mode power supplies may beemployed that utilize power transistor 88 in accordance with theteachings of the present invention.

In one embodiment, power transistor 88 has a blocking voltage ratingcompatible with the peak voltage generated in the power supply circuit.When power transistor 88 is off, a relatively high voltage, which isgreater than or equal to a pinch off voltage V_(P) of power transistor88, may be present across its main terminals 89 and 91. Under thiscondition, the maximum voltage appearing at tap terminal 94 is in oneembodiment significantly reduced from the maximum voltage appearing atmain terminal 89 of power transistor 88, such that the circuit elementsin control circuit 83 are not subjected to excessive voltages inaccordance with the teachings of the present invention.

In one embodiment, start-up circuitry 95 of control circuit 83 mayemploy the use of tap element 90 for a start-up function. For example,in the embodiment illustrated in FIG. 4, tap terminal 94 provides avoltage to a regulator 92 and a resistor 99 included in control circuit83. To start up the power supply, current is drawn through the primarywinding 76, power transistor 88 via tap element 90, and regulator 92 tocharge up bypass capacitor 110. When the voltage at node 112 reaches thedesired level, regulator 92 may be turned off.

In one embodiment, a line-sense function of control circuit 83 may alsoemploy the use of tap element 90. For example, in the embodimentillustrated in FIG. 4, when the voltage at main terminal 89 decreasesbelow a pinch off voltage, the tap terminal 94 provides a voltage toline sensor 97 that is substantially proportional to the voltagedifference between main terminals 89 and 91 of the power transistor 88.The voltage provided by tap element 90 to line sensor 97 is coupled tothe PWM circuit 104, such that PWM circuit 104 can provide a line sensefunction of control circuit 83. For example, the PWM circuit 104 maystop switching the power transistor 88 when the line voltage falls belowa certain level.

In one embodiment, when power transistor 88 is turned on, a relativelylow voltage appears across its main terminals 89 and 91 and currentflows through the primary winding 76 and the main terminals 89 and 91 ofpower transistor 88. In this mode of operation, the voltage across mainterminals 89 and 91 is below a pinch off voltage and tap element 90therefore provides a voltage at tap terminal 94 that is substantiallyproportional to the current flowing through the main terminals of powertransistor 88 in accordance with the teachings of the present invention.The tap terminal 94 voltage is coupled to the PWM circuit 104, such thatPWM circuit 104 can provide a current limit function of the controlelement. In order to minimize the tolerance of the current limitfunction, it is preferable to package control circuit 82 and powertransistor 88 together and then perform an electrical trimming operationto adjust the current limit of the complete control element 82.

FIG. 5 is a diagram illustrating the relationship between the voltageacross the main terminals and the voltage of a tap terminal of oneembodiment of a power transistor in accordance with the teachings of thepresent invention. The tap terminal voltage increases with increasingvoltage across the main terminals of the power transistor up to acertain level and then remains relatively constant as the voltage acrossthe power transistor is increased further. To illustrate, FIG. 5 showsthe voltage at the tap terminal increasing with the voltage across themain terminals (e.g. between the drain and source terminals of the powerMOSFET) until a pinch off voltage V_(P), which in the illustratedembodiment is approximately 50V. Thus, the maximum voltage of the tapterminal is shown as about 50V in this example, but the maximum voltagecould range from 5 to 150V in other embodiments. FIG. 5 also illustratesthat the maximum voltage of the tap terminal in one embodiment remainssubstantially constant or fixed for voltage levels across the mainterminals of the power transistor greater than or equal to the pinch offvoltage V_(P). In another embodiment, it is noted that the voltage atthe tap terminal may increase with increasing voltage levels across themain terminals of the power transistor as long as the voltage at the tapelement is reduced or limited so as not to subject the circuit elementsin control circuit to excessive voltages in accordance with theteachings of the present invention.

FIG. 6 is a diagram illustrating a cross-sectional side view of oneembodiment of a power transistor 601 in accordance with the teachings ofthe present invention. It is appreciated that although power transistor601 has been illustrated as an n-channel transistor in FIG. 6, ap-channel transistor may be realized by utilizing the oppositeconductivity types for all of the illustrated doped regions.

In one embodiment, power transistor 601 includes an insulated gate 619,including for example polysilicon, drain terminal 605 and sourceterminals 613, which are illustrated as 613A and 613B. N+ source regions621, which are shown as 621A–F, are coupled to source terminals 613 andN+ drain region 603 is coupled to drain terminal 605. N+ source regions621 are adjoining P-body regions 611, which are shown as 611A–C. Aplurality of N− drift regions 607, which are shown as 607A–C, adjoin atone end N+ drain region 603 and extend from the N+ drain region 603 toadjoin at the other end P-body regions 611. In one embodiment, an N− tapdrift region 608 is also included, which also extends from N+ drainregion 603. An N+ tap region 623 adjoins N− tap drift region 608 at theopposite end from N+ drain region 603. A tap element 615 is coupled toN+ tap region 623. In one embodiment, N− tap drift region 608 issubstantially similar to the N− drift regions 607 and may even becharacterized as one of the plurality of N− drift regions 607. Inanother embodiment, N− tap drift region 608 may have a differentconstruction, dimensions, such as for example width, and/or a differentdoping profile than the N− drift regions 607 to optimize or change thepinch off voltage V_(P).

In one embodiment, N− drift regions 607 are separated by P-type regions609 of semiconductor material. As illustrated in FIG. 6, the N− driftregions 607 are separated by P-type regions 609 of semiconductormaterial and are arranged such that alternating regions of N− driftregions 607 and P-type regions 609 of semiconductor material areinterposed among one another in power transistor 601.

In the on state, insulated gate 619 is biased such that channels areformed proximate to insulated gate 619 across P-body regions 611 to formconduction paths between N+ source regions 621 and N− drift regions 607.Accordingly, conduction paths are provided through N− drift regions 607between source electrodes 613 and drain electrode 605. In the off state,insulated gate 619 is biased such that there are no longer channelsunder insulated gate 619 through P-body regions 611 to form conductionpaths between source electrodes 613 and drain electrode 605.

In operation, when N+ drain region 603 is biased at a relatively lowvoltage with respect to N+ source regions 621, tap element 615 isresistively coupled to drain terminal 605 through N+ tap region 623 andthrough N− tap drift region 608. Accordingly, tap element 615 in oneembodiment tracks the voltage of drain terminal 605 and is thereforeproportional to the current through drain terminal 605. In oneembodiment, these conditions occur with the voltage difference betweenthe main terminals, source and drain terminals 613 and 605, is less thanthe pinch off voltage V_(P). However, at a higher drain terminal 605bias, or when the voltage difference between the main terminals, sourceand drain terminals 613 and 605, is greater than or equal to the pinchoff voltage V_(P), a portion of the tap N− type regions 608 issubstantially or completely depleted of free charge carriers by P-typeregions 609 on the neighboring sides of N− tap drift region 608.

In the embodiment illustrated FIG. 6, the P-type regions 609 areillustrated as pillars and are numbered as 609A–C on either sides of N−drift regions 607 as well as N− tap drift region 608. In one embodiment,when the N− drift regions 607 and N− tap drift region 608 are completelydepleted of free charge carriers, the voltage of tap element 615 iseffectively fixed at V_(P) when the voltage difference between the mainterminals, source and drain terminals 613 and 605, is greater than orequal to V_(P), as illustrated for example in FIG. 5.

FIG. 7 is a diagram illustrating a cross-sectional side view of anotherembodiment of a power transistor 701 in accordance with the teachings ofthe present invention. It is appreciated that although power transistor701 has been illustrated as an n-channel transistor in FIG. 7, ap-channel transistor may be realized by utilizing the oppositeconductivity types for all of the illustrated doped regions.

In one embodiment, power transistor 701 includes insulated gates 719,shown as insulated gates 719A–F, drain terminal 705 and source terminals713, which are illustrated as 713A and 713B. N+ source regions 721,which are shown as 721A–D, are coupled to source terminals 713 and N+drain region 703 is coupled to drain terminal 705. N+ source regions 721are adjoining P-body regions 711, which are shown as 711A and 711B. Aplurality of N− drift regions 707, which are shown as 707A and 707B,adjoin at one end N+ drain region 703 and extend from the N+ drainregion 703 to adjoin at the other end P-body regions 711. In oneembodiment, an N− tap drift region 708 is also included, which alsoextends from the N+ drain region 703. An N+ tap region 723 adjoins N−tap drift region 708 at the opposite end from N+ drain region 703. A tapelement 715 is coupled to N+ tap region 723. In one embodiment, N− tapdrift region 708 is substantially similar to the N− drift regions 707and may even be characterized as one of the plurality of N− driftregions 707. In another embodiment, N− tap drift region 708 may have adifferent construction, dimensions, such as for example width, and/or adifferent doping profile than the N− drift regions 707 to optimize orchange the pinch off voltage V_(P).

In one embodiment, N− drift regions 707 and N− tap drift region 708 areseparated by regions of dielectric material 709 in which field plates725 are disposed. As illustrated in the embodiment of FIG. 7, dielectricmaterial regions 709 are shown as 709A–D and in one embodiment mayinclude oxide. Field plates 725 are shown as 725A and 725B and arecoupled to source terminals 713. In the depicted embodiment, the N−drift regions 707 are separated by regions of dielectric material 709and field plates 725 such that alternating regions of N− drift regions707 and regions of dielectric material 709 and field plates 725 areinterposed among one another in power transistor 701.

In the on state, insulated gates 719 are biased such that channels areformed proximate to insulated gates 719 across P-body regions 711 toform conduction paths between N+ source regions 721 and N− drift regions707. Accordingly, conduction paths are provided through N− drift regions707 between source electrodes 713 and drain electrode 705. In the offstate, insulated gates 719 are biased such that there are no longerchannels proximate to insulated gates 719 through P-body regions 711 toform conduction paths between source electrodes 713 and drain electrode705.

In operation, when N+ drain region 703 is biased at a relatively lowvoltage with respect to N+ source regions 721, tap element 715 isresistively coupled to drain terminal 705 through N+ tap region 723 andthrough N− tap drift regions 708. Accordingly, the voltage of tapelement 715 tracks the voltage of drain terminal 705 and is thereforeproportional to the current through drain terminal 705. In oneembodiment, these conditions occur with the voltage difference betweenthe main terminals, source and drain terminals 713 and 705, is less thanthe pinch off voltage V_(P). However, at a higher drain terminal 705bias, or when the voltage difference between the main terminals, sourceand drain terminals 713 and 705, is greater than or equal to the pinchoff voltage V_(P), a portion of the N− drift regions 707 and N− tapdrift region 708 is substantially or completely depleted of free chargecarriers by field plates 725 disposed in the dielectric regions 709 onneighboring sides of N− drift regions 707 and N− tap drift region 708.

The voltage of tap element 715 is effectively fixed at V_(p) when thevoltage difference between the main terminals, source and drainterminals 713 and 705, is greater than or equal to V_(P), as illustratedfor example in FIG. 5.

In the foregoing detailed description, the present invention has beendescribed with reference to specific exemplary embodiments thereof. Itwill, however, be evident that various modifications and changes may bemade thereto without departing from the broader spirit and scope of thepresent invention. The present specification and figures are accordinglyto be regarded as illustrative rather than restrictive.

1. An electronic circuit control element, comprising: a power transistor having first, second, third and fourth terminals; and a control circuit coupled to the third and fourth terminals of the power transistor, wherein a voltage between the fourth and second terminals of the power transistor is substantially proportional to a voltage between the first and second terminals when the voltage between the first and second terminals is less than a pinch off voltage, wherein the voltage between the fourth and second terminals of the power transistor is substantially constant and less than the voltage between the first and second terminals when the voltage between the first and second terminals is greater than the pinch off voltage.
 2. The electronic circuit control element of claim 1 wherein the fourth terminal is coupled to provide power to the control circuit.
 3. The electronic circuit control element of claim 1 wherein the fourth terminal is coupled to a current limit function of the control circuit.
 4. The electronic circuit control element claim 1 wherein the fourth terminal is coupled to a line sense function of the control circuit.
 5. The electronic circuit control element of claim 1 wherein the power transistor and control circuit are packaged together in a single package.
 6. The electronic circuit control element of claim 1 wherein the power transistor is coupled to switch a current between the first and second terminals in response a control signal to be received from the control circuit at the third terminal.
 7. A power supply regulator, comprising: a power transistor having first, second, third and fourth terminals; and a control circuit coupled to the third and fourth terminals of the power transistor, wherein a voltage between the fourth and second terminals is substantially proportional to a voltage between the first and second terminals when the voltage between the first and second terminals is less than a pinch off voltage, wherein the voltage between the fourth and second terminals is substantially constant and less than the voltage between the first and second terminals when the voltage between the first and second terminals is greater than the pinch off voltage.
 8. The power supply regulator of claim 7 wherein the fourth terminal is coupled to provide power to the control circuit.
 9. The power supply regulator of claim 7 wherein the fourth terminal is coupled to a current limit function of the control circuit.
 10. The power supply regulator claim 7 wherein the fourth terminal is coupled to a line sense function of the control circuit.
 11. The power supply regulator of claim 7 wherein the power transistor and control circuit are packaged together in a single package.
 12. The power supply regulator of claim 7 wherein the power transistor is coupled to switch a current between the first and second terminals in response a control signal to be received from the control circuit at the third terminal.
 13. A power supply control element, comprising: a power transistor having first, second, third and fourth terminals; and a control circuit coupled to the third and fourth terminals of the power transistor, wherein a current provided at the fourth terminal of the power transistor is to be drawn from at least one of the first and second terminals of the power transistor to provide power to the control circuit and wherein a voltage between the fourth and second terminals of the power transistor is substantially proportional to a voltage between the first and second terminals when the voltage between the first and second terminals is less than a pinch off voltage.
 14. The power supply control element of claim 13 wherein the voltage between the fourth and second terminals is substantially constant and less than the voltage between the first and second terminals when the voltage between the first and second terminals is greater than the pinch off voltage.
 15. The power supply control element of claim 13 wherein the power transistor is coupled to switch a current between the first and second terminals in response a control signal received from the control circuit at the third terminal.
 16. A power supply control element, comprising: a power transistor having first, second, third and fourth terminals; and a control circuit coupled to the third and fourth terminals of the power transistor, wherein a voltage between the fourth and second terminals is substantially proportional to a voltage between the first and second terminals, the voltage between the fourth and second terminals providing an input signal to a current limit function of the control circuit.
 17. The power supply control element of claim 16 wherein the voltage between the fourth and second terminals of the power transistor is substantially constant and less than the voltage between the first and second terminals when the voltage between the first and second terminals is greater than the pinch off voltage.
 18. The power supply control element of claim 16 the power transistor is coupled to switch a current between the first and second terminals in response a control signal received from the control circuit at the third terminal. 